How to Design for Manufacture and Assembly Value Chain Competitiveness (VCC)

Version: 1 December 2019

This information is provided by Rolls-Royce in good faith based upon the latest information © 2019 Rolls-Royce | Not Subject to Export available to it; no warranty or representation is given; no contractual or other binding Control commitment is implied. 2 How to Design for Manufacture and BACK Map NEXT Assembly

Scope Objectives & Principles

Prerequisites 1. Understand 2. Apply ‘Design ‘Design for Gate Gate Start Check for Manufacture Check Manufacture and list and Assembly’ list Assembly’

End

Scope BACK Map NEXT

This ‘How To’ will enable you to:

• Identify and review the inputs needed to conduct appropriate Design for Manufacture and Assembly (DFMA) at different stages of the product lifecycle • Design for manufacture guidelines • Design for assembly guidelines • DFMA team members with knowledge and experience in cross-functional disciplines • The product, manufacturing and assembly requirements • Approach to conducting DFMA reviews for action capture and closure

Objective and Principles BACK Map NEXT

1. DFMA influences design definition 2. Design for Assembly aims to in the early stages of the product reduce the number of parts, development easing handling and assembly operations Design for Manufacturing and Assembly (DFMA)

Influence on Cost / Quality / Time:

4. DFMA utilises cross-functional 3. Design for Manufacturing aims to knowledge and experiences for select the most cost effective idea generation and action material and process to ease implementation manufacturing operations

Prerequisites BACK Map NEXT

Knowledge: • Existing design development process and potential benefits of adopting a DFMA approach

8 parts, 20 processes 2 parts, 6 processes Concept Design Design for Manufacture and Assembly Detailed Design Design for Manufacture and Assembly (DFMA) • To minimise product cost from product design through its life-cycle • Resulting in simpler products, collaboration in design & manufacture, lean thinking

A. Design for Assembly (DFA) • Design the products for ease of assembly • Focusing on the number of parts, handling and ease of assembly operation

B. Design for Manufacturing (DFM) • Design the components / products for ease of manufacture • Selecting the most cost effective material and process to be used in production

Functional analysis is a design method providing a complete view of design in terms of functions and relationships of those functions

Example functional analysis of a ball point pen

Advantages of functional analysis • The product intended use is examined thoroughly giving a better understanding of the user and customer • The technique aids creative thinking and idea generation (innovation) before selecting the best design solution • It enables the identification and definition of modular functions, promoting the definition of modular product design and components Modular design © 2019 Rolls-Royce 8 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Determine the parts requirement

Reduce the number of unique parts, asking

• Must the part move relative to other parts already installed in the assembly? – It is only unique if movement is essential for product function

• Must the part be made of different material? - It is only unique if material type is essential for product fit, form or function

• Must the part be separate from other parts? – It is only unique if there is a separation requirement for in-service Parts List adjustment or replacement

© 2019 Rolls-Royce 9 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Determine parts standardisation & practical minimum number Can the parts be standardised? • Within the assembly station • Within the full assembly • Within the assembly plant • Within the company

Determine the practical minimum number of parts start • Team assessment of practical changes point • Trade-offs between part cost and assembly cost • Increasing creativity rate required towards theoretical min. no. of parts Cost focus: Minimising number of parts and extra sizes reduces both inventory and confusion during assembly © 2019 Rolls-Royce 10 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Determine parts presentation for ease of assembly • Design out jamming and tangling

Avoid nesting & tangling

• Avoid too small or too large Avoid small items requiring precision placement

Symmetry eliminates • Design for part symmetry reorientation

© 2019 Rolls-Royce 11 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Determine parts handling requirements Considering the current handling techniques: based on assembly process and complexity of parts • How many hands are required? • Is any grasping assistance needed? • What is the effect of part symmetry on assembly? • Is the part easy to align/position? Part handling considerations • Size • Sharpness • Thickness • Stickiness • Nesting • Requires two hands • Weight • Requires grasping tool • Tangles • Requires magnification to be seen • Fragile • Requires mechanical assistance • Slippery

Considering the current insertion (locate & secure) techniques: based on difficulty required for each component insertion a • Is the part secured immediately upon insertion? • Is it necessary to hold down part to maintain location? • Is the part easy to align/position?

Part insertion considerations b c a) Self-aligning parts b) Self locating parts c) Adequate access and visibility

d) One way orientation d e e) Avoid reorientation during assembly

When using mechanical fasteners, attempt to use the lowest cost method: • Snap fitting • Plastic flexing • Riveting • Screwing

Design in the fastener Use “snap together” designs Standardise fasteners

© 2019 Rolls-Royce 14 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Design for mistake proof assembly Design in mistake-proofing in to assembly to prevent • wrong parts being assembled • parts being omitted a • assembling parts in the wrong orientation e Bosses Examples include using b a) Bosses b) Tapers c) Locating holes Tapers d) Part symmetry Asymmetry c e) Part asymmetry d

Locating holes Symmetry

© 2019 Rolls-Royce 15 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Assembly - Secondary operations and other considerations Eliminate secondary operations • Assemble in single axis (from above) - screw, twist, rivet, bend, crimp • Eliminate operations - weld, solder, glue, paint, lubricate, test, measure, adjust

Screw down from above Rivet

Other considerations • Avoid connections • Eliminate restricted access for operations • Avoid adjustments • Minimise part variation Eliminate restricted access © 2019 Rolls-Royce 16 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Manufacture - Considerations for ease of Manufacture When selecting the manufacturing methods: • Is hard tooling required? • Have we selected the best technology or process to fabricate parts? • Have we selected the best material needed for function and cost? • Have we looked at all the new technology that is available? • Are the parts shaped for the implementation of automation? • Is the supplier capable of meeting the specifications?

Other considerations • Parts reduction strategy • reducing manufacturing costs through less purchases, inventory, handling, processing time, development time, equipment, engineering time, inspection, testing, etc. • Raw material choices • Lowest cost choices can drive up the number of materials. Choosing a material with better machining characteristics might result in lower processing costs offsetting higher material cost.

Standard stock sizes • Develop a common set

Standard material types and properties • Develop a common set

Pre-shaping • Develop forming requirements & work with suppliers

© 2019 Rolls-Royce 18 1. Understand ‘Design for Manufacture and BACK Assembly’ Map NEXT Design for Excellence ‘Design for’ (DFX) is not limited to ‘assembly’ (DFA) or ‘manufacture’ (DFM), there are other types for example Design for • Performance • Testability Design • Serviceability for Service • Reliability (DFS) • Yield • Six Sigma Collectively known as DFX

 A better understanding gained of Design for Assembly (DFA) and benefits for ease of assembly operations

 A better understanding gained of Design for Manufacture (DFM) and benefits for ease of manufacturing operations

 Awareness of other ‘Design for’ activity available through DFX

Start Early & Do Regularly

Generate Ideas Design Concepts Design Actions Manufacturing Concepts Manufacturing Actions Historical Problems

• Design for Manufacture and Assembly is a continuous improvement cycle of activity starting at concept design through to final definition • It requires a cross-functional input for effective idea generation and action • The activity needs time & focus, benefiting from facilitation • It is a data-driven activity using existing knowledge and experience • Benefits are only gained through robust action taking and close-out

© 2019 Rolls-Royce 21 2. Apply ‘Design for Manufacture and BACK Assembly’ Map NEXT Manufacturing Technology Planning Define Potential Technologies – Design for Manufacture starts with a good understanding of product functionality and the functional features and the capabilities of manufacturing technology options.

Manufacturing Manufacturing Engineering •Input of Engineering Technology

Technology Data •Potential •Functional Base Technology attribute Technology Sequences Description •Cost Performance Method

Design Core Engineering Technology Technology •Input of Product Selection Selection Characteristics

Product Description TechnologyTechnology A-B-C Product Data Base Selection Technology A-D-C

Match manufacturing process to product functional features Define Functional Features Conduct Design for Manufacture & Assembly • Identify product functional features • Select Technologies based upon their capability to produce the products functional Make Features Select Best features. Process Technology • In selecting the technologies: Capable 1. Consider the capability of the proposed technologies 2. If a technology is not currently Define capable can it be developed to Process become capable? Capability 3. Can product design change to match current technology capability and still meet the functional requirement? © 2019 Rolls-Royce 23 2. Apply ‘Design for Manufacture and BACK Assembly’ Map NEXT Match Product Design to Process Capability

Design for Manufacture - Match non- Define functional product attributes to Functional process capability Features

Conduct Design for Manufacture & Assembly • Confirm the technologies to Make manufacture the product functional Features Select Best Process Technology features. Capable • The design of product non functional features needs to be changed to make their manufacture process capable. These actions will ensure the product design Define Process intent is achieved in manufacture and Capability production.

Production Repair Operations Engineering

Team Service Leadership Purchasing / Quality Engineering Supply Chain Engineering

• DFMA team members should have relevant knowledge and experience covering multiple disciplines, through Design Engineering to Production Operations • A core team will maintain consistency through the development period, possibly bringing in other disciplines as required

© 2019 Rolls-Royce 25 2. Apply ‘Design for Manufacture and BACK Assembly’ Map NEXT Review product, manufacturing and assembly requirements • The team should review appropriate product, manufacturing and assembly requirements at different stages of the lifecycle • It can be helpful, particularly at the early stages to nominate an independent facilitator to run the DFMA reviews. This helps maintain team focus and help achieve a balanced output

DFMA to influence DFMA through design definition • The majority of issues should be reviewed concept in the Concept Stage: • This is where most problems can be solved • As the project matures the Requirements Close out profile requirements for resolution should reduce • Useful review aids to make issues easier to understand include: • 2D printed drawings marked up with identified issues • Projected 3D models • Prototypes in easily produced materials • 3D Printed and/or Stereolithography models • Virtual Manufacturing

© 2019 Rolls-Royce 26 2. Apply ‘Design for Manufacture and BACK Assembly’ Map NEXT Engaging with suppliers- why do it? Engaging with suppliers in DFMA: • Is crucial for influencing and optimising the concept • Helps to develop the manufacturing requirements and identifies potential risks later on in the production phase

Benefits include: • Forming strategic alliances in development of advanced product / process solutions • Supply chain mutual competitive advantage, best use of supplier capabilities and capacities • Cross-functional engagement on capability assessments • Faster technology development and deployment • Global collaboration partnerships delivering technology solutions to market • Leveraging supplier knowledge to achieve cost effective solutions and intelligence

• DfMA activity generates output in the form of ideas and issues • Each idea for improvement or issue to resolve should be ranked and an action to address it

Actions DfMA Tracker Open Closed

Date Raised Action Action Result # Description Type Advantages Disadvantages Rank Action Result 1 2 Raised By Owner Status Status

Cost reduction on Opportunitiy to standaridse tooling and will Dec 12th Joe 1 hole sizes on 5 and 5.5mm Idea prevent mistakes None 1 Update drawing CDG Open 2013 Bloggs holes in casing PCD by having one drill size. Flatness requirement will be hard to achieve with current Unlikley to Unable to open 2 - High milling process, open achieve sealing 1 - big benefits tolerance, Confirm if this is Oct 21st John tollerance to ensure Avoided capital requirement, feature needs 2 Issue Ranking 2 possible to open Design Closed Rejected 2013benefitsDoe thatcapability is acceptable. spend potential for that are easy to • Ranking grindingprovides to a means of drawing tolerance Alternative will require leagage of oil fix and all high achieve are hard to fixinvestment in griding from manifold. prioritisingflatness. actions to be capability. High 1 risks Will need to taken 2 DE to Do weight vs Change material type to be thicken up load- New material cost analysis, ME to the same as Trent 1000 part, Standardised the bearing area to Design incorporated, Nov 30th Jane verify T1000 forging • HighIncorpor benefit/risk and easy to 3 gemoetry is similar so can Idea forging, cost utilise lower 2 ME Closed weight penalty 2013 Doe detail, Purchase to ated utilise same forging 3reduction. capability4 Purchase minimal, cost discuss volume implement actions should be defenition. Low material, benefit £50k /yr Benefit / Risk / Benefit pricing with supplier. 3- Low increased weight. 4 - low benefits Hard Easy pursued for completion first benefits that and risks that are Ease of Implementation • All high risks must be are hard to fix easy to fix © 2019 Rolls-Royce addressed 28 Gate checklist 2: Apply ‘Design for BACK Manufacture and Assembly’ Map

 Understanding gained on the application process for DFMA

 Understanding of design to process capability match and technologies required

 DFMA team formed with knowledge experience across required disciplines

 Product requirements understood and regular review methods in place

 Early supplier engagement considered

 DFMA action capture, ranking and closure tracking in place